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  #805  
Old 01-31-2015, 02:13 AM
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Re: Grand Willys project

Quote:
Originally Posted by Sleeps View Post
Shhh stop posting without more updates!.. getting my hopes all high just to be crushed.

But really great work as always. The jeep is already a work of art and it only gets better as you work on it. Im just sad that i will probably never see it in person.
Ha ha, in replying to this I've just done what you don't want.

Glad to hear the interest is still there.

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  #806  
Old 01-31-2015, 02:28 AM
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Re: Grand Willys project

Sorry guys but doesn't look like I will be able to replace all the lost photos as you don't seem to be able to edit your own posts?
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  #807  
Old 01-31-2015, 04:28 AM
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  #808  
Old 02-04-2015, 02:00 AM
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Re: Grand Willys project

Scott has had a lot of trouble making the affected posts editable. Doesn't seem to be an easy way to do it unfortunately.
I will leave updating in case I have to add at least the lost year, plus up to now, to the end of this thread. That way there wont be too much doubling up.

Cheers and thanks for the support over the years guys.
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  #809  
Old 02-04-2015, 11:40 AM
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Quote:
Originally Posted by Gojeep View Post
Scott has had a lot of trouble making the effected posts editable. Doesn't seem to be an easy way to do it unfortunately.
I will leave updating in case I have to add at least the lost year, plus up to now, to the end of this thread. That way there wont be too much doubling up.

Cheers and thanks for the support over the years guys.
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  #810  
Old 02-09-2015, 05:36 PM
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Re: Grand Willys project

A big thank you to Scott who went to the effort of making this thread editable for me so I could replace all the lost pictures that were hosted on Facebook.
Thanks mate.

Anyone new to this thread who missed all off 2014's post and then some, can go back to page 57 and read on from there to page 65. There were some missing photos in the first 10 pages as well that I have fixed up.

Back to normal programming now and can post the last update you missed from last week.

Cheers Marcus
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  #811  
Old 02-09-2015, 05:37 PM
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Re: Grand Willys project


Before welding the cowl back together, I want to do anything that needs to be done while it is easier in pieces. One thing is to make these early Landcruiser cast bonnet hinges fit the cowl.


They need to be level left to right across the cowl so that don't bind. So have to come up with a way to do that and still look factory.


I have a piece of cowl from a Landcruiser that shows how they did it. I was originally going to cut these into the Willys cowl and call it done. But only one was usable due to the rust on the other one on the underside.


First thing I did was grind down some plate with a 9" grinder to the angle I needed.


Cut the plate out the same shape as the hinge and checked to see it it leveled it.


Then did a test on some scrap the same thickness to see if my idea would work. I drilled and tapped the bench to the hinge hole pattern. I will place over that the angled piece of plate followed by the scrap test piece and then bolt the hinge piece over it to keep it all in place.


Can just see the angled piece underneath with it all together.


Then hammered down around the edge using a chasing tool like I practised on the grille headlight holes I did while camping.


Looks like it could work.


I have made the piece less rounded than the original Landcrusier pressing in the foreground as wanted it closer in shape to the base of the hinge.


So now to try it on the Willys cowl. I first had to flatten out the bead so I could screw down the hinge flat. I decided to cut a slot with a hacksaw so the bead each side would not be pulled down in the process where I didn't want it.


I heated it with a torch as I wanted it to shrink at the same time. When getting closer to the edge to save risking a miss hit, I hit down on my hammer like this to get right into the corner.


Assembled with the angled form underneath and screwed it all down to the bench.


A few minutes later, hey presto!


Ready to see if the angle is right.


Clamped back down to the firewall and looks to have worked.


Forgot to take a photo of this bit on the other side, but this worked well to get the corner done.


Other one finished.


With the Willys stamping raised up as well, think it fits in with the utilitarian look I'm going for.


Noticed that it has pulled down a bit though behind the hinge pressing. Will have to address that.


I placed a piece of rubber on the bench and then flipped the cowl upside down and hammed lightly around the edge of the pressing. I used the rubber as didn't want any stretching while flattening out the edge of the pressing. This brought the dip back out.


The Landcruiser thread plate floats underneath to give some adjustment. Was badly rusted so will make new ones.


I cut the same metric threads as original so can buy the matching screws to suit the hinges. The area and plate was coated in zinc before assembly and again after plug welding the piece that holds it in place.
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  #812  
Old 02-09-2015, 07:06 PM
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Re: Grand Willys project

Glad to see everything is back on track.
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  #813  
Old 02-09-2015, 08:52 PM
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Quote:
Originally Posted by Gojeep View Post
A big thank you to Scott who went to the effort of making this thread editable for me so I could replace all the lost pictures that were hosted on Facebook.
Thanks mate.

Anyone new to this thread who missed all off 2014's post and then some, can go back to page 57 and read on from there to page 65. There were some missing photos in the first 10 pages as well that I have fixed up.

Back to normal programming now and can post the last update you missed from last week.

Cheers Marcus
Great to see you fixed it!.. Scott is the man.
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  #814  
Old 02-14-2015, 05:08 AM
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Re: Grand Willys project


Well after the success of repairing the other set of bonnet louvers, thought I would try making some from scratch for the side of the cowl that better matched than the ones from the FJ45.


Transferred the shape of the louver to some 8 mm/ 5/16" flat I had. Used a holesaw to get a start and then nibbled away at it with a jigsaw and then a file.


This is a little thicker than the height of the louvers, but would allow for some spring back. The middle part was cut out just using a angle grinder.


Tig welded it onto more of the same flat to get a good base to it and stop the sides from spreading. Filled it with oil to cool as might add a little hardness to it without getting brittle like a water quench.


Using a great tip from Per, MetalMan Sweden, I used a wood chisel sharpened with a curve to the end to cut the metal. Could also drill a small hole at each end and use a thin cutting disc, but leaves a bigger hole not covered by the louver.


Used a bit of very hard red gum to shape into a forming tool. It is important that it is the full width of the louver.


First louver done on new metal.


I made sure the thickness each side of the lower form I cut out matched the spacing between the louvers of the bonnet ones.


I found starting in the corners and lots of small taps to just cut through the metal and no further worked best for me. I scribed lines to follow where to cut and made sure the metal didn't move on the form. You need to hit down right on the very edge for it to work.


Halfway there. Quite like just the three as would match the ribbing, but have done the calculations and not enough area to match the intake of the A/C unit.


I kept the form straight to get consistent shape. The corners need to be a bit ahead of the rest and use plenty of light taps with the mallet working back and forth like a reciprocating machine.


Matches the shape of the template pretty well.


One thing that did show up when I did this one starting from the top, when forming the next louver, it tended to pull the bottom of the louver above it into the form.


I have just started the second one and doing it the other way and stays straight and flatter as have more metal above it.


Seems to be matching quite well so think they are will be good enough to use. I will redo the first one though to get it to stay in better shape.


The bonnet ones taper in length which is not needed for the cowl sides. So took the length of the middle one which was 152 mm/6", to make the new ones. That is an inch longer than the original side ones from the Landcruiser.
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  #815  
Old 02-22-2015, 03:19 AM
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Re: Grand Willys project

Just finishing off the louvres. Like to add another tip on cutting them. At first I was hitting too hard and would blunt the chisel straight away. Found it did a better job, and saved the chisel more, by first going along the line rocking the chisel while tapping it lightly. Then go along again cutting all the way through but never letting the points of the chisel touch the metal. Only needed to lightly sand the chisel between louvres to keep it sharp.

I modified the former a bit by adding the extra piece you can see in the lighter coloured timber. What this did was make the top edge of the louvre sit down flat without twisting up the louvre which is what would happen if you just hit it down with a mallet on its own after the louvre was formed. It also further controlled the depth of the louvre making them all very consistent.


Now to set out where they will go. I held the front guard in place against the edge of the cowl so I could mark where the top of it was. I wanted the slot of the last louvre to line up with this.


Then made sure it was square to the door A pillar which made it parallel to the bottom of the door sill too.


Showing the other side now but lets you see how much bigger the cut out will be than the original Landcruiser vents I was going to fit.


Good gaps around it ready for welding.


Can see the shrinking of the weld has effected the bottom louvre slot. More planishing is needed to flatten it out along the weld line.


Straightened out pretty well.


The two together should provide enough fresh air to the intake of the A/C unit.


Doesn't look too bad. Function over form as like my fresh air yet still keep the windows up so it is quieter for long drives.
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  #816  
Old 02-28-2015, 03:09 AM
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Re: Grand Willys project

Hardly got to touch it this week I'm afraid as got way laid with my back seizing up again for a few days. Least it not a few weeks like it used to be each time, so pleased about that.


Just clamped a few panels together to see where I am at and make sure it fits the image I had in my head. Need to stand back some times just to make sure you are on track.
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